Translation of the Original Operating Manual Rotary feed-through DDF-S/-KS Assembly and Operating Manual Superior Clamping and Gripping
Imprint Imprint Copyright: This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely supplied to our customers and operators of our products and forms part of the product. This documentation may not be duplicated or made accessible to third parties, in particular competitive companies, without our prior permission. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: 0389017 Edition: 01.00 22/05/2015 en SCHUNK GmbH & Co. KG All rights reserved. Dear customer, congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for the highest precision, top quality and best service. You are going to increase the process reliability of your production and achieve best machining results to the customer's complete satisfaction. SCHUNK products are inspiring. Our detailed assembly and operation manual will support you. Do you have further questions? You may contact us at any time even after purchase. Kindest Regards Yours SCHUNK GmbH & Co. KG Spann- und Greiftechnik Bahnhofstr. 106 134 D-74348 Lauffen/Neckar Tel. +49-7133-103-0 Fax +49-7133-103-2399 info@de.schunk.com www.schunk.com 2 01.00 DDF-S/-KS 25-200 en
Table of Contents Table of Contents 1 About this manual... 4 1.1 Warnings... 4 1.2 Applicable documents... 4 2 Basic safety notes... 5 2.1 Intended use... 5 2.2 Not intended use... 5 2.3 Environmental and operating conditions... 5 2.4 Product safety... 6 2.4.1 Protective equipment... 6 2.4.2 Constructional changes, attachments, or modifications... 6 2.5 Personnel qualification... 6 2.6 The use of personal protective equipment... 6 2.7 Notes on particular risks... 7 3 Warranty... 8 4 Scope of delivery... 9 5 Technical data... 10 6 Assembly... 11 6.1 Mounting the DDF on the robot... 12 6.2 Air connections... 14 6.3 Electrical connection... 15 7 Trouble shooting... 16 7.1 Does the DDF let out air when shutdown?... 16 7.2 Does the DDF let out air when in operation?... 16 7.3 Electric signals are not transmitted?... 16 8 Maintenance and care... 17 8.1 Maintenance and lubrication intervals... 17 8.2 Lubricants/Lubrication points... 17 8.3 Disassembly of the module... 18 8.4 Servicing and assembling the module... 19 9 Assembly drawings... 20 9.1 Assembly Drawing DDF 31 / 40 / 50... 20 9.2 Assembly Drawing DDF 40-1 / 50-1 / 63... 21 9.3 Assembly Drawing 80 / 80-1 / 100 / 100-1 / 125 / 125-1 / 160 / 160-1 / 200... 22 10 Sealing Kit... 23 11 Enclosed Pack... 24 01.00 DDF-S/-KS 25-200 en 3
About this manual 1 1.1 About this manual This instruction is an integral part of the product and contains important information for a safe and proper assembly, commissioning, operation, maintenance and help for easier trouble shooting. Before using the product, read and note the instructions, especially the chapter "Basic safety notes". Warnings To make risks clear, the following signal words and symbols are used for safety notes. DANGER Danger for persons. Non-compliance will inevitably cause irreversible injury or death. WARNING Dangers for persons. Ignoring a safety note like this can lead to irreversible injury and even death. CAUTION Dangers for persons. Non-observance can cause minor injuries. NOTICE Material damage Information about avoiding material damage. 1.2 Applicable documents General terms of business Catalog data sheet of the purchased product The documents listed here, can be downloaded on our homepage www.schunk.com 4 01.00 DDF-S/-KS 25-200 en
Basic safety notes 2 2.1 Basic safety notes Intended use The rotary feed-through was designed to transfer the energy (electrical signals and air) to the handling module in robotic applications with endless rotation. The product is intended for installation in a machine/system. The requirements of the applicable guidelines must be observed and complied with. The product may be used only in the context of its defined application parameters ( 5, Page 10). The product is designed for industrial use. To use this unit as intended, it is also essential to observe the technical data and installation and operation notes in this manual and to comply with the maintenance intervals. 2.2 Not intended use Use which is not specified as an intended use is for instance when the product is for example used as a pressing tool, stamping tool, lifting tool, guide for tools, cutting tool, tensioning mean, boring tool. 2.3 Environmental and operating conditions Make sure that the product has a sufficient size for the application. Observe Maintenance and lubrication intervals ( 8.1, Page 17). Make sure that the environment is free from splash water and vapors as well as from abrasion or processing dust. Exceptions are products that are designed especially for contaminated environments. 01.00 DDF-S/-KS 25-200 en 5
Basic safety notes 2.4 Product safety Dangers arise from the product, if: the product is not used in accordance with its intended purpose. the product is not installed or maintained properly. the safety and installation notes are not observed. Avoid any manner of working that may interfere with the function and operational safety of the product. Wear protective equipment. NOTE More information are contained in the relevant chapters. 2.4.1 Protective equipment Provide protective equipment per EC Machinery Directive. 2.4.2 Constructional changes, attachments, or modifications Additional drill holes, threads, or attachments that are not offered as accessories by SCHUNK may be attached only with permission of SCHUNK. 2.5 Personnel qualification The assembly, initial commissioning, maintenance, and repair of the product may be performed only by trained specialist personnel. Every person called upon by the operator to work on the product must have read and understood the complete assembly and operating manual, especially the chapter "Basic safety notes" ( 2, Page 5). This applies particularly to personnel only used occasionally, such as maintenance personnel. 2.6 The use of personal protective equipment When installing or removing the product, observe the relevant health and safety at work rules and use the required personal protective equipment (protective gloves, safety boots and safety goggles). 6 01.00 DDF-S/-KS 25-200 en
Basic safety notes 2.7 Notes on particular risks The general rule is: Remove the energy supplies before installation, modification, maintenance, or adjustment work. Ensure that no residual energy remains in the system. Do not move parts by hand when the energy supply is connected. Do not reach into the open mechanism or the movement area of the unit. Perform maintenance, modifications, and additions outside the danger zone. For all work, secure the product against accidental operation. Take particular care during maintenance and disassembly. Only qualified personnel may disassemble the product. CAUTION Possible risk of injury due to electrostatic energy! Components or assembly groups may become electrostatically charged. When touched, the electrostatic discharge can trigger a startle response, which can result in injuries. The operator must ensure that all components and assembly groups are included in the local equipotential bonding in line with the applicable regulations. NOTE The equipotential bonding must be installed by a specialist electrician in line with the applicable regulations, paying particular attention to the actual conditions in the working environment. The effectiveness of the equipotential bonding must be verified by a specialist electrician through regular safety measurements. WARNING Risk of injury from objects falling and being ejected The danger zone must be surrounded by a safety fence during operation. WARNING Risk of injury when the machine/system moves unexpectedly. 01.00 DDF-S/-KS 25-200 en 7
Scope of delivery 3 Warranty If the product is used as intended, the warranty is valid for 24 months from the date of delivery from the production facility under the following conditions: Intended use in 1-shift operation Observe the mandatory maintenance and lubrication intervals Observe the environmental and operating conditions Parts touching the work piece and wear parts are not part of the warranty. 8 01.00 DDF-S/-KS 25-200 en
Scope of delivery 4 Scope of delivery The scope of delivery includes Rotary feed-through DDF-S/-KS in the ordered model. Accessory pack 01.00 DDF-S/-KS 25-200 en 9
Technical data 5 Technical data More technical data are included in the catalog data sheet. Whichever is the latest version. DDF 31-S 40-S 50-S 63- KS 80- KS 100- KS 125- KS Weight [kg] 0.5 0.9 0.95 2.2 5.4 5.6 13.5 14 Max. rotation speed [min-1] 120 120 120 110 100 100 90 90 Max. rotational speed [ /s] 720 720 720 660 600 600 540 540 Continuous torque [Nm] 1.0 1.5 1.5 6.0 20.0 20.0 42.0 42.0 Starting torque [Nm] (after standstill) Rotation Energy transmission 160- KS 1.5 2.5 2.5 8.0 32.0 32.0 60.0 60.0 unbegrenzt Air (air pressure up to 10 bar) 2x 2x 2x 4x 4x 4x 4x 4x Electrical Energy electrical signals; with max. 60V; 1A 4x 4x 4x 6x 6x 6x 10x 10x Noise emission [db(a)] 70 70 70 70 70 70 70 70 DDF 40-1- KS 50-1- KS 80-1- KS 100-1-KS 125-1-KS Weight [kg] 2.0 2.1 11.0 11.3 21.0 22.0 Max. rotation speed [min-1] 110 110 90 90 70 70 160-1-KS Max. rotational speed [ /s] 660 660 540 540 420 420 Continuous torque [Nm] 6.0 6.0 42.0 42.0 65.0 65.0 Starting torque [Nm] (after standstill) Rotation Energy transmission 8.0 8.0 60.0 60.0 95.0 95.0 unbegrenzt Air (air pressure up to 10 bar) 4x 4x 4x 4x 4x 4x Electrical Energy electrical signals; with max. 60V; 1A 6x 6x 10x 10x 10x 10x Noise emission [db(a)] 70 70 70 70 70 70 10 01.00 DDF-S/-KS 25-200 en
Assembly 6 Assembly WARNING Risk of injury during assembly! Switch off the energy supply. 1 2 3 4 1 The torque support (shaft) must be mounted on the nonmoving housing of the robot. 2 Shaft with shaft-ø ( 6.1, Page 12) 3 Bracket on the DDF (included in the DDF scope of delivery) 4 The shaft for the torque support (torque pin) should run precisely parallel to the»middle axis«of the DDF and at a»right angle«(90 ) to the bracket. 01.00 DDF-S/-KS 25-200 en 11
Assembly 6.1 Check the evenness of the bolting surface Mounting the DDF on the robot The values relate to the entire bolting surface. Requirements for levelness of the bolting surface (Dimensions in mm) Diameter Permissible unevenness < 100 < 0.02 > 100 < 0.05 The following figure is an example image. It serves for illustration and assignment of the spare parts. Variations are possible depending on size and variant. Assembly of the DDF 12 01.00 DDF-S/-KS 25-200 en
Assembly 1 Shaft for torque support 2 DDF bracket 3 Tool, e.g. PGN gripper type from SCHUNK 4 Robot with interface according to DIN ISO 9409 5 Rotary feed-through from SCHUNK 6 Cylindrical pin (in accessory pack) 7 Base with interface according to DIN ISO 9409 for connecting to robot 8 Seals for sealing air ducts between shaft and flange (in accessory pack) 9 Screws for mounting the base on the robot flange (in accessory pack)(number varies depending on the size) 10 Cylindrical pin for positioning the base with shaft 11 Shaft completely pre-assembled 12 Cylindrical pins for positioning the shaft and flange (only in connection with flange (14)) 13 Screws for fastening the shaft onto the base (number varies depending on the size) 14 Flange with interface DIN ISO 9409 for tool-mounting (e.g. gripper) (only optional - on special order) 15 Screws for assembly of shaft and flange (only in connection with flange (14)) Shaft-Ø of the torque support Type DDF-S/-KS 25 and 31 DDF-S/-KS 40 and 50 DDF-S/-KS 40-1 and 50-1 DDF-S/-KS 63 DDF-S/-KS 80 and 100 DDF-S/-KS 80-1 and 100-1 DDF-S/-KS 125 and 160 DDF-S/-KS 125-1 and 160-1 Shaft-Ø of the torque support Ø 9 mm Ø 11 mm Ø 11 mm Ø 11 mm Ø 17 mm Ø 23 mm Ø 23 mm Ø 29 mm 1 Fasten the base (7) on the robot interface with the screws (9) from the accessory pack.the cylindrical pin (6) from the accessory pack can be used for centering the base (7). 2 Insert the cylindrical pin (10) into the base. 3 Place the completely assembled shaft (11) onto the base. NOTICE! This pre-assembled unit must not be separated 4 Screw together the shaft (11) and the base (7) with the screws (13). 5 Insert the seals (8 for sealing the air ducts) and insert the cylindrical pins (12) into the shaft. 01.00 DDF-S/-KS 25-200 en 13
Assembly 6 Fasten the flange (optional, on special order) with the screws (15) onto the shaft (11). Screw tightening torques Screw M5 M6 M8 M10 M12 Tightening torque [Nm] 10 Nm 17 Nm 40 Nm 80 Nm 140 Nm 6.2 Air connections WARNING Risk of injury during connection! Switch off the energy supply. NOTICE Observe the requirements for the air supply ( 5, Page 10). The precise positions and options for the air connections are shown in the SCHUNK catalog. air connections 1 Air connections, robot side 2 Air connections, tool-side 3 Air purge connection Open only the air connections that are needed. Close unused main air connections using the screw plugs from the enclosed pack. For a hose-free direction connection, use the O-rings from the enclosed pack. 14 01.00 DDF-S/-KS 25-200 en
Assembly 6.3 Electrical connection WARNING Risk of injury when the machine/system moves unexpectedly! Switch off power supply. Pin assignments NOTE Electrical energy: max. 60 volts, 1 amp 1 2 2 1 1 Tool-side: Flange receptacle 2 Robot-side: Flanged panel plug Pin assignments Size Flange receptacle Flanged panel plug Notes DDF-S/-KS 25 / 31 / 40 / 50 DDF-S/-KS 40-1 / 50-1 / 63 / 80 / 100 PIN 7 not connected DDF-S/-KS 80-1 / 100-1 / 125 / 125-1 / 160 / 160-1 / 200 PIN L and M not connected 01.00 DDF-S/-KS 25-200 en 15
Trouble shooting 7 7.1 Trouble shooting Does the DDF let out air when shutdown? Possible cause Corrective action Air connection not installed correctly Tighten air connection ( 6.2, Page 14) Connections that are not in use are not closed Close connections 7.2 Does the DDF let out air when in operation? Possible cause Components have become loose e.g. through over-loading. Solution(s) Send the module to SCHUNK with a repair order or disassemble module. 7.3 Electric signals are not transmitted? Possible cause Cable is not connected correctly Strands swapped Bussignals are to be transmitted Collector ring defect Corrective action Check if the circular connectors and the miniature flat connectors are plugged in correctly. Check, if strands are swapped. Observe Pinassignment. Bus signals can not be transferred. Send the module to SCHUNK with a repair order. 16 01.00 DDF-S/-KS 25-200 en
Maintenance and care 8 8.1 Maintenance and care Maintenance and lubrication intervals NOTICE At ambient temperature above 60 C the lubricants can harden faster. Interval decrease accordingly. Maintenance- and lubrication interval Interval [Mio. cycles] 1,5 8.2 Lubricants/Lubrication points We recommend the lubricants listed. During maintenance, treat all greased areas with lubricant. Thinly apply lubricant with a lint-free cloth. Lubricant point Lubricant Metallic sliding surfaces Fin Assembly Grease (Interflon) All seals Renolit HLT 2 01.00 DDF-S/-KS 25-200 en 17
Maintenance and care 8.3 Disassembly of the module Position of the position numbers ( 9, Page 20) WARNING Risk of injury due to spring forces! The lid is under spring tension. Carefully disassemble the module. NOTICE Do not damage any seals during assembly! Treat the slip ring contacts of the electrical feed-through with the greatest possible care and do not touch them. 1 Remove compressed air lines. 2 Detach cable connections. 3 Completely unscrew the screws (30 and 34). 4 Pull shaft (1) from robot flange (3). NOTICE! Robot flange (3) and shaft (1) are bolted together (20). 5 Unscrew the screws (44). 6 Pull the ring (4) carefully from the shaft (81). 7 Pull the protective housing (6) carefully from the shaft (1). NOTICE The contacts of the slip ring unit must not come into contact with the shaft (1) or be touched. 8 Remove all seals according to sealing kit list ( 10, Page 23). 9 Thoroughly clean all parts (except for slip-ring contacts in the cover housing (6)) and check all parts for any defects and wear. 10 Carefully clean the slip ring tracks in the shaft (1) with a clean cloth and lightly lubricate the tracks with a clean cloth and oil. 11 Replace all seals according to sealing kit list ( 10, Page 23). 18 01.00 DDF-S/-KS 25-200 en
Maintenance and care 8.4 Maintenance Servicing and assembling the module Clean all parts thoroughly and check for damage and wear. Replace all wear parts / seals. The seals are in the enclosed sealing kit. ( 10, Page 23) Treat all greased areas with lubricant. ( 8.2, Page 17) Oil or grease bare external steel parts. Assembly Assembly takes place in the opposite order to disassembly. Observe the following: Unless otherwise specified, secure all screws and nuts with Loctite no. 30243 and tighten with the appropriate tightening torque. Screw tightening torques Screw M5 M6 M8 M10 M12 Tightening torque [Nm] 10 Nm 17 Nm 40 Nm 80 Nm 140 Nm 01.00 DDF-S/-KS 25-200 en 19
Assembly drawings 9 9.1 Assembly drawings The following figures are example images. They serve for illustration and assignment of the spare parts. Variations are possible depending on size and variant. Assembly Drawing DDF 31 / 40 / 50 Assembly DDF 25 / 31 / 40 / 50 * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Item 75 only for DDF 25 and 31 **** Optional - only in conjunction with item 82 20 01.00 DDF-S/-KS 25-200 en
Assembly drawings 9.2 Assembly Drawing DDF 40-1 / 50-1 / 63 Assembly DDF 40-1 / 50-1 / 63 * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in conjunction with item 82 01.00 DDF-S/-KS 25-200 en 21
Assembly drawings 9.3 Assembly Drawing 80 / 80-1 / 100 / 100-1 / 125 / 125-1 / 160 / 160-1 / 200 Assembly 80 / 80-1 / 100 / 100-1 / 125 / 125-1 / 160 / 160-1 / 200 * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Item 29 not with DDF 160 **** Item 31 only for DDF 125 / 125-1 / 160 / 160-1 / 200 ***** Optional - only in conjunction with item 82 22 01.00 DDF-S/-KS 25-200 en
Sealing Kit 10 Sealing Kit ID.-No. of the seal kit Seal kit for ID number DDF 31-S 0371032 DDF 40-S / 50-S 0371033 DDF 40-1-KS / 50-1-KS 0371034 DDF 63-KS 0371035 DDF 80-KS 5516845 DDF 80-1-KS / 100-1-KS 5516847 DDF 100-KS 5516846 DDF 125-KS 5516849 DDF 125-1-KS 5516851 DDF 160-KS 5516850 DDF 160-1-KS 5516852 DDF 200-KS 5516854 Contents of the seal kit ( 9, Page 20). 01.00 DDF-S/-KS 25-200 en 23
Enclosed Pack 11 Enclosed Pack ID.-No. of the accessory pack Accessory pack for ID number DDF 31-S 5516043 DDF 40-S / 40-1-KS 5516044 DDF 50-S / 50-1-KS 5516045 DDF 63-KS 5516046 DDF 80-KS 5516047 DDF 80-1-KS 5516052 DDF 100-KS 5516048 DDF 100-1-KS 5516053 DDF 125-KS 5516049 DDF 125-1-KS 5516054 DDF 160-KS 5516050 DDF 160-1-KS 5516055 DDF 200-KS 5516051 Contents of the accessories pack ( 9, Page 20). 24 01.00 DDF-S/-KS 25-200 en